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Weathering Steel

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. A technical overview of
. weathering steels for bridges
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. and general construction
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. The Plate Professionals
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Mittal Steel USA - Plate
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Introduction
The rich patina of Weathering Steel is being seen more often in unpainted applications for bridges, utility
and sign poles, structures and highway guardrails.

The aesthetic values of this weathered and textured material, and more importantly, the practical values
of Weathering Steel make this steel particularly useful for applications where strength, ease of fabrication
and appearance are paramount. This brochure provides owners, designers, structural engineers, bridge
engineers and contractors important information about Weathering Steel including its use, handling,
fabrication, availability, properties and specifications.

Design Considerations
Weathering Steel has a unique, natural oxide coating that when fully mature is dense, tightly adherent
and relatively impervious to further atmospheric corrosion. Minor damage to this oxide coating heals
itself; therefore, maintenance is greatly reduced.

Bare Weathering Steel is suitable for many atmospheric environments, including moderate industrial and
select marine exposures. It is compatible with other construction materials – brick, stone and wood –
when appropriate details are incorporated in the design.

Weathering Steel is available with yield strengths of 50 ksi, 70 ksi and 100 ksi allowing designs with
relatively light sections. When combined with the fact little or no painting is required, Weathering Steel
provides significant first cost and life cycle cost savings.

The Weathering Process


Alloy content and environmental conditions are key factors influencing the formation of an oxide film on
steel. Under appropriate atmospheric conditions, Weathering steel develops a durable, tightly adherent
protective oxide coating. The appearance, texture and maturity of this coating depend on three
interrelated factors: time, degree of exposure and atmospheric environment.

With time, the oxide coating changes from a “rusty” red-orange to a dark purple-brown patina. The
moderately rough texture becomes more distinct as the coating thickens. This weathering process
extends over a period of time and depends on the following factors:

• Degree of exposure has a strong influence on


the weathering process. Steel exposed to
rain, sun and wind weathers more quickly
than steel in a sheltered location. The oxide
on a sheltered surface tends to be rougher,
less dense and less uniform.

• Atmospheric environment also impacts oxide


development. Frequent wet-dry cycles – for
instance moisture in the form of rainfall and
dew that is dried by wind and sun – are key to
the weathering process.

• The degree of atmospheric contamination


also has its effect. In moderate industrial
environments, Weathering Steel usually
matures rapidly and achieves the darkest
possible tone. In rural locations, the oxide
coating develops more slowly, and generally
has a lighter tone. In arid climates, the
weathering process is dramatically slower.
Today, corrosion engineers can use new analytical tools to identify the type of oxides formed in an
environment. The presence of “good” or “bad” oxides can confirm whether the protective patina has or
will be formed.

Weathering Steel has been successfully used in many applications. Growing use in bridges has resulted
in over 40% of all structural steel used in bridges to be weathering steel. However, there are conditions
where bare unpainted weathering steel may have problems developing a protective oxide patina.
Examples of these conditions are:

• Atmospheres containing
concentrated, corrosive
industrial or chemical fumes

• Locations subjected to salt-


water spray or salt-laden fog

• Applications where the steel


is continuously submerged in
water, buried in soil or
installed where water run-off
is contaminated with deicing
salts (during winter months)
or drains through leaky seals,
open joints or expansion
dams.

• Applications where the steel


is in direct contact with timber
decking. Timber retains
moisture and may be treated
with salt bearing
preservatives.

• Bridges over enclosed


highways where
concentrated salt-laden road
sprays under the bridge
accumulate on the
superstructure.

Questions also have been raised regarding the effect of acid rain on the corrosion resistance of uncoated
weathering steel. Research conducted by Mittal Steel USA indicates the effect of acid rain can be
ignored. Wet deposition of sulfur dioxide, as in acid rain, actually has a beneficial effect on weathering
steel because the acid rain washes away dry deposits that may increase corrosion.

Similarly, concerns regarding the effects of diesel engine exhaust gases on overhead structures have
been expressed. An industry-sponsored study concluded the corrosive effect of these gases on
uncoated Weathering Steel structures was negligible. The combustion products of diesel fuel, when
combined with steam, are dissipated to the atmosphere. Only soot, unburned fuel and its decomposition
products could be deposited on the steel, all of which are non-corrosive toward steel.

The FHWA has issued a technical advisory entitled “Uncoated Weathering Steel Structures” which
provides the latest and most complete information available concerning the proper application of
Weathering Steel in highway structures. Produced by the Federal Highway Administration (FHWA), Mittal
Steel USA has reprinted this advisory as Technical Bulletin TB-307, which is available upon request. This
advisory applies not only to bridges, but also to all structures including light, sign and electrical
distribution poles and structures. A precise evaluation of the suitability of uncoated Weathering Steel for
a particular site may be obtained from a corrosion consultant and/or conducting standardized
environmental tests.

In the past, long-term exposure testing of Weathering Steels indicated these steels have atmospheric
corrosion resistance of approximately two times that of carbon structural steel with copper or about four
times carbon structural steel without copper (copper 0.02 max.). ASTM now provides a standard guide
(G101) describing more meaningful methods for estimating the atmospheric corrosion resistance of low-
alloy Weathering Steels on the basis of chemical composition or alternative prediction of long-term
performance on the basis of short-term data.

Weathering Steel Grades


The definition of what is a weathering steel is contained in ASTM G101. Two formulae are available for
predicting performance. The most recent Townsend formula is applicable to the widest chemistry
contents for structural steels. A summary of the ratings for a number of Mittal Steel USA grades is given
in the following figure:

Mittal Steel USA


Weathering Steels Ranking
Townsend Weathering Index from G101
10

5
HPS 50W Spartan V Spartan II Spartan III
HPS 70W HPS 100W HSLA-100 HSLA-100
A588
50W A514F Spartan I Spartan A1010
Cor-Ten® B 100W A710A IV Duracorr®
T-1® HSLA-80 HSLA-100
The most popular weathering steel, ASTM A588, also known as Cor-Ten® B, is most widely used in
bridges as ASTM A709 Grade 50W. New high performance steels (HPS) for bridges have predicted
improved weathering performance. These grades are available as A709 Grades HPS 50W, HPS 70W
and HPS 100W. U. S. Navy steels HSLA-80 and HSLA-100 produced to MIL-S-24645 have significantly
improved because of their high levels of copper (1.1%) and nickel (1.5 – 3.5%). They are dual certified to
the Mittal Steel USA SpartanTM family of Cu-Ni alloy steels. The 12% chromium, Duracorr®, is a utility
stainless steel, which is finding applications in coal cars and coal handling equipment and most recently
in bridge applications. Research is ongoing to confirm the performance of these highly alloyed improved
weathering steels in short and long term testing.

Cleaning and Handling


Proper preparation of the surface of the steel by sand or grit blasting is necessary where rapid weathering
and uniform appearance are desired. By removing all mill scale, the surface oxide will start forming on
hot-rolled steel as it cools in air. This preparation is recommended especially for the highly visible
exterior or fascia members of bridges.

Care should be taken while handling Weathering Steel in the field to avoid unsightly gouges and scrapes.
The material should be kept as clean as possible away from mud, grease, oil, paint, concrete, mortar
splatter and other foreign substances to minimize costly cleaning. Paint or crayon identification marks
should be made in locations not visible on the finished structure. Otherwise, these marks must be
removed from the visible surfaces during the final cleaning operation.

Storage in transit, yards or at job sites should be minimized. When storage is unavoidable, uneven
weathering can be minimized by positioning the material in an exposed area with good drainage.
Blocking, to avoid contact with the ground, is essential. Cover cloths also may prevent water staining and
dirt accumulation, thus minimizing problems of an initial, non-uniform weathered appearance.

In general, the corrosion resistance and appearance of Weathering Steel is not affected by cleanliness.
Mill scale and minor soilage will weather off naturally on exposed surfaces and need not be a concern for
interior members of low visibility. However, cleanliness and surface preparation are important where an
early, uniform appearance is desired.

Joining, Forming and Stiffening


Good connection, forming and stiffening details are important with Weathering Steel. Ledges, crevices
and pockets that hold water, water-laden debris or condensation for an extended period time must be
avoided. The oxide coating will not develop on surfaces that are continually wet or covered with debris.
Under such circumstances, corrosion continues in these areas.

Welding
Weathering Steel is readily weldable by the submerged-arc, shielded metal-arc, gas metal-arc and flux-
cored arc welding process. Procedures are similar to those used for other low-alloy structural steels.
Low-hydrogen electrodes are specified by the American Welding Society for welding Weathering Steel.
Suggestions on minimum preheat are contained in the latest revisions of ANSI/AWS “Structural Welding
Code” D1.1 and the ANSI/AASHTO/AWS “Bridge Welding Code” D1.5.

For bare steel applications, when the weld is required to have strength, corrosion resistance and
weathered appearance similar to that of the base metal, special electrodes must be used.

When matching strength is required, and color match and corrosion resistance are not important, E70,
E80, E90, E100 or E110 low-hydrogen electrodes may be used. These electrodes also work for the
underlying passes in multiple-pass welds. However, when color match and corrosion resistance are
important, appropriate alloy electrodes must be used for the final two exposed top layers.

All welding should be consistent with AWS recommended procedures including adequate edge
preparation and preheating, the selection of proper flux (when applicable) and the use of properly dried,
low-hydrogen electrodes and fluxes.
Oxygen Cutting
Weathering Steel can be cut with conventional oxygen-gas equipment using the same general
procedures for other structural steels. The workmanship requirements outlined in ANSI/AWS D1.1 and
ANSI/AASHTO/AWS D1.5, Part 3 should be observed.

Mechanical Fasteners
Fasteners used to attach Weathering Steel to other materials should provide a corrosion resistance and
weathered appearance comparable to the base material. High-strength structural bolts, including
appropriate nuts and hardened washers, are available in Weathering Steel.

In certain circumstances, it may be desirable to use another type of fastener. For instance, galvanized
fasteners have been used for highway guardrails. Whereas fundamental electrochemical and
thermodynamic considerations predict a decreased life of the galvanized coating, this does not appear to
be a limiting factor. Part of this success can be attributed to the thick coatings applied in hot-dip
processing – typically 3 to 5 mils – giving a longer life expectancy. A light colored stain on the weathering
steel, just beneath the galvanized fasteners, results from the rundown of zinc corrosion products. If
appearance is critical, galvanized fasteners should not be used.

In bolted connections, the space between the two surfaces of Weathering Steel will usually seal itself with
the typical tight oxide if the joint is tight and immobile. If the joint moves, both surfaces should be coated
with protective material and filled with a suitable sealant to avoid progressive corrosion.

Bolt Spacing
In making a riveted, bolted or welding joint, fastener spacing should be such that the joint is tight and
moisture cannot enter between the plys of material. If moisture enters the joint, corrosion may cause
prying of the joint (also called “packout”) or fastener failure. AASHTO provides guidelines with respect to
fastener patterns and spacing to prevent this problem.

Overlapping Surfaces
In overlapping joints, such as those common in utility distribution and high mast light poles, water can be
drawn into the joint area by capillary action. This causes a breakdown of the normal oxide formation and
“pack rust” forms. These joints should be sealed to prevent water intrusion or the lap area contact
surfaces should be coated to prevent rust formation.

Forming and Fabricating


Weathering Steel can be fabricated with conventional equipment, tools and methods normally used for
other steels with the same strength level.
Suggestions and Details for Bridges
Corrosion Control Study
Studies indicate the most important factor leading to excessive corrosion of bridges is the runoff of water
contaminated with deicing salts through leaking deck seals, expansion dams or open joints. To minimize
this problem, the following should be considered:

• Eliminate joints whenever


possible. Jointless bridges up to
400 ft in length have been used
successfully. Such designs
incorporate integral abutments
with piling flexible enough to
accommodate girder translations.
Bridges up to 1600 ft. in length
with joints only at the abutments
likewise have performed
successfully. The combination of
Weathering Steel and jointless or
minimum joint decks offers
owners structures of long-term
durability and low maintenance
cost.

• Use troughs beneath open finger-


type joints as part of a system to
discharge runoff away from the
superstructure elements.

• Seal all other joints. Neoprene


compression seals are commonly
used in this application.
However, experience indicates
many of these do leak over time
due to traffic and bridge
movements.

• Recognize the potential for


leakage through sealed joints and
overflow from blocked troughs.
Provide a second line of defense
by coating the girders beneath
deck joints. Typical distances for
this partial painting are 1 to 1-1/2
times the girder depth on either
side of the joint.

• Control roadway drainage.


Minimize scuppers to maximize
flow and prevent blockage. Divert
approach roadway drainage away
from the bridge structure.
Provide adequate drainage
beneath overpass structures to
prevent ponding and continual
traffic spray from below.
Another factor important to the success of Weathering Steel structures is the elimination of any
details that prevent normal wet-dry cycles. The retention of water, dirt and other debris must be
avoided and natural drainage should be designed into the structure. Tubular and box sections
should be sealed or adequately vented to allow air circulation, prevent condensation and allow for
drainage.

Methods of Minimize Staining


Like most steel compositions, Weathering Steel releases dissolved iron when water washes over
exposed surfaces. The precipitation of the dissolved iron can cause staining on adjacent surfaces,
particularly when the steel is subjected to frequent rainfall during its early months of exposure. If
these adjacent surfaces are light in color and/or porous in nature, this staining may be
objectionable. Although staining potential usually decreases as the oxide is formed, it may be
present for an indefinite period, depending on environmental factors.

The best way to minimize staining is to incorporate permanent design details that divert water away
from adjacent vulnerable materials. In bridge construction, the most severe staining occurs prior to
deck placement. Designers use a number of details, and combinations thereof, to cope with
staining. Temporary polyethylene coverings, gutter and downspout systems, adequate overhangs,
drip plates and special flashing usually accomplish the job.

Applying liquid silicone or other type sealers is another method to reduce stain penetration into
porous masonry. Some surface discoloration may occur, but may not be objectionable. These
“stained” sealed coatings fade and weather off with time. Staining also can be removed by using
proprietary chemical removers or, if necessary, sandblast cleaning. Caution should be exercised in
using stain removers and manufacturer’s recommendations should be followed.

Drip Pans
In several installations, steel or fiberglass pans
have been placed under the bearings and
cantilevered out from the pier. These pans direct
rust-laden water away from the piers to a
location where major staining will not occur.
However, where piers are very high, this system
may permit winds to blow rust-laden water back
onto the pier surface.

Sloping Abutments, Pier Details and


Drains
On abutments and piers, various combinations of
sloping and concave surfaces used in
conjunction with drains provide an economical
method of minimizing staining. The rust-laden
runoff water is directed to areas that are not
readily visible. Drains collect this water and
carry it away.
Drip Plates
A small plate attached to the bottom flange of a
girder can divert water off the structure before it
runs onto another bridge component.

Polyethylene Covering
One method of minimizing staining prior to deck
placement is to cover the pier caps with a
polyethylene sheet which will not be easily
damaged by wind gusts and construction
operations until the bridge deck is poured.
Remove the sheet once the deck is in place and
a system is installed to carry away the rust-laden
water. This technique also has been used
successfully with pier coatings.

Preformed Elastomeric Compression


Joints
Preformed elastomeric compression joints, when
installed and functioning properly, provide a
thorough seal against deck surface water.
These joints help prevent water from draining
through and staining the substructure surfaces.

Pier Coatings
To reduce penetration by rust stain, liquid silicon sealers or other formulations can be applied to porous
materials such as brick, stone and concrete. Designers using this method of protection must understand
that the pier may be discolored by the treatment. Although the coating reduces stain penetration, some
surface discoloration may occur because of oxide deposits. Coatings may disappear with time allowing
the piers to develop a natural color.

Cleanup
Staining is not a new or unique problem for Weathering Steel. All structural materials stain. If all
preventive measures fail, stained areas can be cleaned by sandblasting or use of several proprietary
chemical stain removers.
Summary
Staining is most severe when Weathering Steel is subjected to prolonged rainfall during early months of
exposure, and protection is most important during this initial phase. Nightly condensation is the best
aging agent available and does not usually result in significant staining.

Inspection and Maintenance


Effective inspection and maintenance programs are essential to the performance of all structures, not just
those built with Weathering Steel. Particular attention should be given to drainage systems on and
beneath the structure and its approaches. Troughs must be kept open and sealed joints resealed.
Debris and salt deposits should be periodically flushed from the structure particularly beneath joints and
around the bearings. Vegetation should be cleared from pier and abutment areas to enhance air
circulation and the subsequent weathering of the steel.

Fatigue
The issue of fatigue life of uncoated Weathering Steel has been addressed by the AASHTO
Subcommittee on Bridges and Structures. The subcommittee concluded Weathering Steel could be
considered the equivalent of painted steels in evaluating fatigue life for all AASHTO stress categories
except Category A. The allowable stress ranges for Weathering Steel Category A details are noted
separately by AASHTO in the current specification. Category A is essentially the base metal in either a
rolled section or a plate. This is the area of the highest allowable ranges and typically does not control
the design of a member.

Protective Coatings
In general, Weathering Steel is intended for and is most often used in a bare, uncoated, exposed
condition. However, surfaces on which prolonged periods of moisture occur should be protected. A good
quality, rust-inhibitive primer applied on cleaned material is usually adequate.

All submerged or buried members, or portions of members imbedded in concrete, soil or gravel pockets,
should have an adequate protective coating like those used on carbon steel in the same environments.
The protection should extend above the interface of the embedment for several inches.

Weathering Steel can be readily painted or coated as regular carbon steel. In its unweathered condition,
a good wire brushing and solvent washdown is adequate to remove loose material, dirt and other
contaminants before painting with a chromate oil-based paint. For synthetic resin paint (vinyl, epoxy,
acrylic or alkyd) and inorganic zinc systems, blast cleaning or the equivalent is suggested.

Availability of Weathering Steel


Availability of Weathering Steel in small quantities is an important consideration. Minimum mill quantities
are available, but quantities vary with the specific grade(s) required. We suggest you get in touch with
the Mittal Steel USA sales office to determine minimum quantities of a product.

When developing design details, consideration also should be given to consolidation of sizes and
thicknesses to overcome the problem of small quantity availability.

General Remarks
Cleaning the Steel
A clean steel surface is necessary for a more uniform weathered appearance. Mill scale and other
foreign matter should be removed so that the steel surface is uniformly exposed to the atmosphere. This
is particularly important if a uniform weathered appearance is desired as early as possible. The mill scale
on Weathering Steel is much tighter than mill scale on ordinary carbon steels.
Removal of mill scale will require a greater effort than with plain carbon steel. Areas not cleaned properly
will not oxidize in a uniform manner. The result will be a mottled appearance for several months or even
years, depending upon degree of exposure and the local environment.

Cleaning is required only if the initial appearance of the steel is important. The steel’s long-term
corrosion properties are not affected measurably by surface preparation.

How Much is Enough?


For most applications, “Commercial Blast Cleaning” (SSPC-SP 6) is sufficient to provide somewhat
uniform weathering of the fully exposed steel. “Blast Cleaning to White Metal” (SSPC-SP5) will provide a
better surface than “Commercial Blast Cleaning”, but will cost significantly more. “Blast Cleaning to White
Metal” is not generally required and should be considered only where a high degree of uniformity is
necessary during the early stages of weathering.

“Near-White Blast Cleaning” (SSPC-SP 10) provides for an intermediate level of surface preparation.
This specification suggests the overall blast-cleaning should be not less than two-thirds nor more than
95% of that required to produce a white metal finish on the same surface

In some instances, it may be necessary to remove heavy coatings of oil or grease with a suitable solvent
prior to the blast-cleaning operation. Removal of the oil and grease permits more efficient blast cleaning.

Further Information

Contact Alex Wilson at Mittal Steel USA at 610-383-3105.

IMPORTANT: The information provided herein is based on testing or Mittal Steel USA’s experience and is
accurate and realistic to the best of our knowledge at the time of publication. However, characteristics
described or implied may not apply in all situations. Mittal Steel USA reserves the right to make changes in
practices that may render some information outdated or obsolete. In cases where specific plate properties
are desired, Mittal Steel USA should be consulted for current information and/or capabilities.

Mill locations: Mittal Steel USA


Burns Harbor, IN ARC Building
Coatesville, PA 139 Modena Road, P.O. Box 3001
Conshohocken, PA Coatesville, PA 19320-0911
1-800-966-5352
www.mittalsteel.com

March 1 , 2004

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